MPS 1-F / MPS 2-F Manual Powder System - eko-BHL

25MPS 1-F / MPS 2-F

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Operating Instructions and Spare Parts List

MPS 1-F / MPS 2-F Manual Powder System

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continued

Table of contents

Directions for use

Safety rules for the electrostatic powder coating

Technical data for the MPS 1-F and MPS 2-F

About these Operating Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

MPS 1-F / MPS 2-F Manual powder system for electrostatic coating . . . . . . . . . . . . . 21. Fields of application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22. Scope of delivery for MPS 1-F (standard): . . . . . . . . . . . . . . . . . . . . . . . . . . 23. Supplementary material for MPS 2-F (standard) . . . . . . . . . . . . . . . . . . . . . 2

Functional description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation of powder coating equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4MPS 1-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Converting MPS 1-F to MPS 2-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Procedure for converting MPS 1-F to MPS 2-F . . . . . . . . . . . . . . . . . . . . . . . . 5Procedure for converting the Main compressed air input connection . . . . . . 5

Preparatory steps for initial start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6a) Setting the correct line voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6b) Connection to the compressed air supply . . . . . . . . . . . . . . . . . . . . . . . . . . 6c) Connecting the venting hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6d) Establishing the ground connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6e) Connecting the PG 1 powder gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7f) Functional check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8g) Filling the powder hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9a) Powder fluidization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9b) Adjusting the powder output and powder cloud . . . . . . . . . . . . . . . . . . . . . 9c) Powder coating - Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10d) Shut-down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10e) Rinsing the powder hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Colour change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Powder hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12PG 1 Powder gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12


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Table of contents (cont.)

Trouble shooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Supplementary material for converting MPS 1-F to MPS 2-F . . . . . . . . . . . . . . . . . . . 15

Pneumatic diagram for MPS F-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Spare Parts Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ordering Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19PH 50-D Powder hopper for MPS 1-F / MPS 2-F . . . . . . . . . . . . . . . . . . . . . 20Fluidizing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22MPS 1-F - MPS 2-F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Directions for use

The electrostatic manual coating system consists of:

PG 1 Electrostatic manual powder coating gunPGC 1 Control module with CB 1 electronics control board50 l Fluidizing powder hopper

This equipment is matched and should only be operated in this configuration.

This equipment combination was tested by PTB:

PTB test No Ex-91.C.9102, Date 10/1991

Safety rules for the electrostatic powder coating

1. This equipment can be dangerous when it is not operated according to the followingstandards:EN 50 050 (or VDE 0745 Part 100),EN 50 053 Part 2 (or VDE 0745 Part 102).

2. All electrostatic conductive parts which are within 5 metres of the coating area andespecially the workpieces must be grounded.

3. The floor in the coating area must be electrostatic conductive. Normal concrete isgenerally conductive.

4. The operating personnel must wear electrostatic conductive footwear, i.e. leathersoles.

5. The operating personnel should hold the gun in the bare hand. If gloves are worn theymust be electrostatically conductive.

6. Connect the grounding cable (green/yellow) supplied to the grounding terminal on thetransport trolley column. The grounding cable must have a good metal to metal contactwith the coating booth, recovery unit, and the work piece conveyor system, especiallywith the workpiece suspension.

7. The electrical cables and powder feed hoses to the gun must be laid out so that theyare protected from possible mechanical damage.

8. The powder coating equipment should only be switched on after the coating booth isin operation. If the booth breaks down then the powder coating equipment must alsobe switched off.

9. Check the grounding of all electrostatic conductive parts at least once a week.

10. When cleaning the gun or changing nozzles the control module must be switched off.

11. Only those parts listed in the section - Nozzle Combinations for PG 1 - of the SpareParts List of the PG 1 Powder Gun may be used.


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Technical data for the MPS 1-F and MPS 2-F

electrostatic coating equipment

Type MPS 1-F MPS 2-F

Electrical data

Single-phase ACSelectable voltage : 100 V, 110 V, 120 V, 200 V, 230 V or 240 VVoltage selection is made on the inside of the electrical unit by resoldering the tag of the transformer.The value of the fuse for 100, 110, and 120 V is 0,5 AT and for the higher voltages is 0,25 AT.

The equipment is delivered for operation at 230 V from the factory.

Tolerance: ±10%Frequency : 50/60 HzConnected load : 60 VA 120 VARated output voltage (to gun) : 10 V 10VRated output current (to gun) : 1.2 VA 1.2 VAType of protection : IP 54Temperature range : +10° C to +40° C (+50°F to +104° F)Approval : EN 50 050,

PTB test No Ex-91.C.9102Date PTB tested 10/1991,

FM No. J.I. OW 7 A 6.AE (7264)Date tested 10/1993

Pneumatic data

Maximum input pressure: 10 barMinimum input pressure: 5 barMaximum water vapour content of compressed air: 1.3 g/m3

Maximum oil vapour content of compressed air: 0.1 mg/kg (oil/water)

Maximum compressed air consumption:Powder hose - ø 11mm 10 m3/h 17 m3/h

Main compressed air input connection thread: 1/4" B.S.P (female)

Dimensions

Width: 460 mm 460 mmDepth: 710 mm 710 mmHeight: 1080 mm 1170 mmWeight: 44 kg 60 kgCapacity: 50 l (~25 kg) 50 l (~25 kg)

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About these operating instructions

These operating instructions contain important information which is required to operate theMPS Manual Powder System. It will guide you safely through the assembly phase, give youinformation to convert an MPS 1 to MPS 2 and give instructions and tips for optimizing thenew powder coating system. The information about functioning of the individual systemcomponents – PGC 1 Powder Gun Control, PG 1 Manual Powder Gun or PI Injector – arefound in the accompanying documentation.

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MPS 1-F / MPS 2-F Manual powder system for electrostatic coating

1. Fields of application

The MPS 1-F / MPS 2-F electrostatic manual powder coating system with the PG 1 powdergun are especially suited for manual coating of workpieces manufactured in small series.

2. Scope of delivery for MPS 1-F (standard):

A PGC 1 control module (1), installed in ametal housing, complete with gun support (2)and power cable.

A transport trolley (4).

A powder hopper (7) with inspection coverand venting hose.

A pressure reducing valve for fluidizing air (3),mounted on the transport trolley column.

A PI 3 (6) plug-in injector.

A PG 1 manual powder gun (5) with electriccable, powder hose, rinsing air hose, and astandard PG 1 nozzle set (see PG 1 OperatingInstructions).

Pneumatic hoses for the conveying air (red),supplementary air (blue), and fluidizing air(black), also pneumatic connection frompressure reducing valve (3) to control module.

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1 PGC 1 control module2 Gun holder3 Pressure reducing valve4 Transport trolley

5 PG 1 Powder gun6 PI 3 injector7 Powder hopper

3. Supplementary material for MPS 2-F (standard)

- A PGC 1 control module, complete with gun support, and special power cable.- A PI 3 injector.- A PG 1 manual powder gun with electric cable, powder hose, and rinsing air hose.- Pneumatic hoses for the conveying air (red), supplementary air (blue), also a pneumatic

connection with a double air distributor from the pressure valve to control module.- Two connecting plates.

Figure 1

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Functional description

The fluidized powder in the powder hopper is sucked up into the injector by the conveyingair (1 - red hose) passing through it. The powder/air mixture reaches the gun through thepowder hose (2). The powder is electrostatically charged shortly before it leaves the gunnozzle. An electrostatic field also exists between the gun nozzle and the groundedworkpiece. The electrostatically charged powder sprayed onto the work piece adheres to thelatter’s surfaces. The powder is fluidized in the hopper by forcing air from below through aporous plastic plate. The fluidized powder acquires liquid-like properties.The conveying air and the supplementary air are regulated on the control module, and thefluidizing air on the trolley column.The function of the injector is explained in the description in the PI Injector Operating In-structions.The arrows in Figure 2 show the directions of flow.

Main compressed air input

Figure 2

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Installation of powder coating equipment

MPS 1-F

The powder coating equipment is preassembled in the factory to a point where only certaincables and hoses must be connected. Refer to the assembly drawing (page 15, Figure 9).

- The gun support can be mounted on either side of the control module housing.A pressure gauge is mounted on the outlet side of the pressure reducing valve on thecolumn of the trolley.

- Connect the thick black hose from the external compressed air input (mounted on thecolumn of the trolley) to the inlet 1.1 IN (10) at the rear of the control module.

- Fit the red hose to the conveying air outlet 1.2 (9) at the rear of the control module andthe other end to the angular fitting of the injector.

- Connect the blue hose for the supplementary air to the outlet 1.3 (8) of the controlmodule and to the straight fitting of the injector.

- Connect the rinsing air hose (small diameter transparent hose) to the connection on thegun and the other end to the outlet 1.4 (7) at the rear of the control module.

- Connect the fluidizing air (ø 6 mm black hose), fitted to the pressure valve, mounted onthe column of the trolley, to the elbow fitting at the bottom of the powder hopper bed(see to page 15, Figure 9).

Rear panel

B CMains connection

1.4 1.3 1.21.1 IN

4.5 ...10 bar

65 ...145 PSIType PGC 1

1 2 3 4 5 6 7 8

F1 F2AGun

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1 Gun socket (A Gun)2 Fluidizing air solenoid valve socket (B)3 Fuse holder (F1)4 Module ground connection5 Fuse holder (F2) for N. America only

6 Mains connection (C)7 Rinsing air connection (1.4)8 Supplementary air connection (1.3)9 Conveying air connection (1.2)

10 External compressed air input (1.1 IN)

Figure 3

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Converting MPS 1-F to MPS 2-F

The MPS 2-F consists of a basic MPS 1-F which has been expanded with supplementary material tooperate with a second manual powder gun, as shown on page 15, Figure 9.

Procedure for converting MPS 1-F to MPS 2-F

1. Remove the small plastic cap from the suction tube hole in the powder hopper lid. Place thesecond suction tube (7) into the hole from below and screw the locking nut (8) tight.

2. Remove the milled nuts, and gun holder from the control unit.3. Mount a connecting plate (4 - slots

facing upwards) and gun holder (9) oneach side on the protruding studs andfasten the milled nuts.

4. Mount the second PGC 1 control unit(2) so that the protruding studs fit intothe slots of the connecting plates andtighten the milled nuts.

5. Fit the second injector (10) into theinjector holder of the second suctiontube in the hopper lid, and check thatit sits firmly, then connect the Convey-ing air connection (13 - red), and theSupplementary air connection (12 -black) to corresponding quick-releaseconnection (red-red, and black-black)of the injector.

6. Remove the plugs from sockets - B,and - C on the rear of the original PGC1 control unit (the other end of thecable from socket - B, is connected tothe solenoid valve on the fluidizing unitand must also be removed). See Fig. 3, page 4.

7. Connect the plug of the second manual Powder gun (1)to socket - A Gun, the Rinsing air hose to air output -1.4, and the Main air hose (3 - black) to air input - 1.1 IN

on the rear of the second PGC 1 unit.8. Connect one of the power cable (6) plugs to socket - B,

on the rear of each PGC 1 unit, and the other end tothe solenoid valve connection of the fluidizing unit.

9. Fit the screw coupling of the Conveying air hose (13 -red) to air output - 1.2, and the Supplementary air hose(12 - black) to air output - 1.3, on the rear of the secondPGC 1 unit, then push the corresponding quick-releaseconnection onto the corresponding injector connection(red to red, and black to black).

10. Connect one plug of the Mains cable (11) to socket - Con the rear of each PGC 1 unit.

Procedure for converting the Main compressed air input connection(See Fig. 4)

1. Unscrew the double air connection adapter from the fluidizing unit fitted on the bracket on thecolumn. Always use the correct size spanners!!!

2. Fit the air connection rings (a), and gaskets (c) on the triple air connection adapter (b) and screwinto the supporting plate adapter.

Figure 4

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GEMAVOLSTATIC

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Preparatory steps for initial start-up

a) Setting the correct line voltage

The factory always sets the voltage to 220 V. If the local line voltage is not 220 V, the voltagesetting of the transformer must be changed by an electrician.

If the incoming voltage is 10% or higher than the voltage selected

damage may be done to internal components. If the incoming voltage

is 10% or more below the selected setting then the unit may operate

erratically or not at all.

1. Unfasten all connections (pneumatic and electrical) at the rear of the control module.2. Unscrew the retaining screw at the rear of the control module.3. Slide the module out carefully and place on a clean, flat surface.

When removing the unit do not pull on the control knobs, push the

unit from the back if necessary.

4. Unscrew the two screws holding the cover of theelectrical section. Carefully remove the coverplate

5. Unsolder the connecting wire from the 220 V terminalpost on the transformer and resolder onto the desiredvoltage terminal post.Do not unsolder the other wire (0) on the trans-

former.

6. Replace the cover and tighten the two screws.When replacing the cover care should be taken thatthe gasket is not displaced.

7. Reinsert the module into the housing and slide backinto place. Tighten the retaining screw.

8. Refasten all pneumatic and electrical connections.

b) Connection to the compressed air supply

Compressed air is fed into the connection on the pressure reducing valve mounted on the trolleycolumn. Thread connection: 1/4" B.S.P.Before connecting, the fluidizing air must be switched off!

The compressed air must be free of oil and water.

c) Connecting the venting hose

1. Push one end of hose over the sleeve on the lid of the powder hopper.2. Place the opposite end into the opening of the booth.

Atmospheric pressure should prevail in the powder hopper while it is

in operation!

d) Establishing the ground connection

Connect the ground connection cable clip on the column of the trolley to the booth or the workpiece suspension device, connect the cable with the cable shoe to the ground connector of thepowder hopper, and the cable with the eye to the ground connector at the rear of the controlmodule.

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Figure 5

CAUTION

CAUTION

NOTICE

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e) Connecting the PG 1 powder gun

1. Connect the cable (1) with the 7-pin connector to the socket labelled "A Gun" at therear of the control module.

2. Connect the hose for rinsing air (9) to rinsing air outlet 1.4 and to the gun.3. Connect the powder hose (7) to the gun and to the injector (6).

1 Gun cable2 Solenoid valve cable3 Mains power input cable4 Internal air input hose5 Conveying air hose6 PI 3 injector7 Powder hose

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B CMains connection

1.4 1.3 1.21.1 IN

4.5 ...10 bar65 ...145 PSIType PGC 1

F1 F2A Gun

8 Supplementary air hose9 Rinsing air hose

10 External compressed air input11 Fluidizing air setting knob12 Fluidizing air hose connection13 Fluidizing air gauge

Figure 6

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f) Functional check

See trouble shooting guide on pages 13 and 14 for malfunctions.1. Switch on the main switch (9) of the control module. The MPS 1-F is under power

when the lamp inside the green main switch illuminates.2. Depress the high-voltage control knob (8) on the control module, if not already in this

position, and turn to the left-hand stop.3. Squeeze the gun trigger. The lowest left-hand LED on the high-voltage / corona current

meter (7) should illuminate. The equipment is active.4. Pick up the gun and point it towards a grounded workpiece approximately 20 cm away.5. Set the pressure for the desired rate of powder deposit (see PGC Control unit Operat-

ing Instructions ) on the conveying air pressure gauge (2). The maximum output is 3.5bar.

6. Check on the supplementary air flowmeter (4) if the ball "floats" within the green sectorof the scale. If it does not, turn the supplementary air control knob (3) to the left orright, while pulling the trigger once or twice, until the ball is positioned correctly.

7. Set the rinsing air by turning the rinsing air control knob (5) until the ball in the rinsingair flowmeter (6) "floats" within the respective green sector of the scale depending onthe type of jet nozzle being used (flat jet nozzle or round jet nozzle).

g) Filling the powder hopper

1. Open the inspection cover from the powder filling hole of the powder hopper.2. Pour the fresh powder into the hopper (max. 50 l/25 kg powder).

The powder should only be filled to a level of approximately 5-10 cm below the handlesof the hopper because when the powder is fluidized a cloud of powder can escapefrom the hopper.

3. Close the inspection cover.

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When all the above checks have been successfully completed, the gun is ready for use. If itfails to function correctly, consult the trouble shooting guide on pages 13 and 14.

Figure 7

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Start-up

a) Powder fluidization

The fluidizing of the powder is dependent on the type of powder, the air humidity, and theambient temperature. Fluidization functions after the control module is switched on.

1. Open the inspection cover of powder hopper.2. Slowly increase fluidizing air. The powder should “boil” only lightly, but constantly. If

necessary increase the fluidizing air until the “boiling” in the hopper is even, thenreduce the air until a low "boil" is obtained.

3. Lock the setting of the pressure reducing valve (mounted on the trolley column) bypushing the knob down.

4. Close the inspection cover.

b) Adjusting the powder output and powder cloud

The powder output is dependent on the type of powder, the powder hose length, thenumber of coils, the powder hose diameter, the conveying air pressure, and the dosing air.The operating principle of the injector and the influence of the supplementary air are ex-plained in the PI Injector Operating Instructions.

1. Switch the control module on.2. Check the powder fluidization.3. Direct the gun into the booth and press gun trigger.4. Set the conveying air (see the PGC Contol unit Operating Instructions).5. Adjust the supplementary air (see the PGC Contol unit Operating Instructions).6. Adjust the rinsing air pressure.

Using a flat jet nozzle- Adjust the pressure gauge (2 - Fig. 7) on the control module to the desired powder feed

rate (see the PGC Contol unit Operating Instructions).- Adjust the supplementary air on the flowmeter (4 - Fig. 7) so that the ball "floats" within

the green sector on the scale.- Adjust the rinsing air on the flowmeter (6 - Fig. 7) so that the ball "floats" in the lower

green sector on the scale.Using a round nozzle with vented deflector

- Adjust the pressure gauge (2 - Fig. 7) on the control module to the desired powder feedrate (see the PGC Operating Instructions).

- Adjust the supplementary air on the flowmeter (4 - Fig.7) so that the ball "floats" withinthe green sector on the scale.

- Adjust the rinsing air on the flowmeter (6 - Fig. 7) so that the ball "floats" in the uppergreen sector on the scale.

7. Adjust the powder cloud.Using a flat jet nozzle

- Loosen the threaded nut with the special box key (see PG 1 Operating Instructions) byturning it approximately 45° so that the flat jet nozzle (or the extension) can barely beturned.


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- Turn the flat jet nozzle in the desired axial direction.- Tighten the threaded nut.

Using a round nozzle with vented deflector- Change the deflector (ø 16, 24, and 32 mm are supplied with the gun).

Never turn the deflectors, these are pushed on an O-ring fitting!

c) Powder coating - Start-up

First check that all electrostatically conductive parts within 5 m

of the coating booth are grounded.

1. Switch on the control module.2. Check powder fluidization.3. Pick up the gun and point it into the coating booth, but not at the work piece to be

coated.4. Press the gun trigger (See PG 1 Operating Instructions).5. Adjust the high-voltage:

Check by observing the LED (See PG 1 Operating Instructions)6. The workpiece(s) can now be coated.

d) Shut-down

1. Release the gun switch.2. Switch off the control module.

The adjustement for high-voltage, rinsing air, and powder output must not be changed.3. For work interruptions such as lunchbreaks, over-night, etc. it is only necessary to

disconnect the compressed air supply.

e) Rinsing the powder hose

Before long idle periods the residual powder must be removed from the powder hose asfollows:

1. Pull out the hose.2. Point the gun into the booth.3. Blow out the hose manually with a compressed air gun.4. Refit the hose to the injector sleeve.

IMPORTANT

NOTICE

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Colour change

1. Drain and clean powder hopper, refer to PH Powder hopper Operating Instructions.2. Blow out powder hose with compressed air.

Powder hose is easy to clean with a piece of foam rubber (approx ø15 mm) which isblown through the hose under pressure.

3. Disassemble and clean the gun, refer to PG 1 Operating Instructions.4. Prepare control module for operation with new powder, refer to PG 1 Operating In-

structions.5. Before starting with the coating operation, “flush” powder hose and gun with the new

powder.

Maintenance schedule

Conscientious maintenance at regular intervals increases the service life of the coatingequipment and will result in uniform coating quality over a longer period!

a) Daily maintenance

1a Clean injector, refer to PI Operating Instructions.2a Clean gun, refer to PG 1 Operating Instructions.3a Clean powder hopper, see "Colour change, section 2" above.

b) Weekly maintenance

1b Clean the powder hopper, injector, and gun. Do not refill the powder hopper untilcoating is to be resumed!

2b Check ground connections between control module, coating booth, workpiece suspen-sion device or the conveyor chain.

c) If the control module remains idle for several days.

1c Disconnect power plug.2c Clean the control module (refer to 1b).3c Disconnect compressed air supply to the coating equipment.


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Cleaning

Powder hopper

Cleaning

1. Disconnect quick-release couplings of fluidizing air hose.2. Remove injector.3. Disconnect ground cable.4. Remove cover and wipe with a clean, dry brush and a clean cloth.5. Clean fluizing/suction tube and injector seal.6. Empty residual powder into a container.7. Vacuum out powder hopper, especially the bed.8. Wipe powder hopper with a clean, dry cloth.9. Reassemble powder hopper.

Do not refill with powder until coating operation is to be resumed

and do not wash hopper bed with solvent or water!

PG 1 Powder gun

Cleaning

Frequent cleaning of the gun is recommended for assuring the coating quality.

Before cleaning the gun, switch off the control module and detach

the gun connector at the gun socket (A Gun).

The compressed air used for cleaning should be free of oil and

water.

Daily:

1. Clean the outside of the gun.

Weekly:

2. Detach the powder hose at the connector.3. Detach the nozzle from the gun and clean it (see PG 1 Operating Instructions).4. Blow out the gun through the powder inlet in the direction of flow.5. Clean the gun tube (see PG 1 Operating Instructions) with the spiral brush supplied .6. Blow out the gun with compressed air again.7. Clean powder hose8. Reassemble and reconnect the gun.

NOTICE

IMPORTANT

13MPS 1-F / MPS 2-F

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Faults

Green lamp does not illumi-nate although control mod-ule has been switched on.

Powder is not fluidized

Needle of pressure gauge forconveying air stays at zerowhen making adjustments

During spraying process airescapes from the gun shaft

Causes

No power:– Control unit is not connected

to Mains

– Fuse F1 defect

– External power line fusedefect

In equipment:– Lamp defect

– Electronics board (PCB)defective

In the gun:– Gun cable defective

– High voltage section defect

– Pneumatic unit is notconnected to compressedair network

– Pressure reducing valvedefect

Operating error:– Module is not switched on

– Gun switch is not pressed

In equipment:– Solenoid valve defective

– Electronics board (PCB)defect

– O-ring defect or missing

Remedies

Connect sprayer withpower cord to Mains

Replace

Replace or reset

Replace

Mail in for repair

Replace, eventual mail infor repairs

Mail in gun for possible repairs

Connect

Replace

Switch on

Press gun switch whileregulating

Replace

Mail in for repair

Replace or insert

Trouble shooting guide


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Faults

Gun does not spray powderalthough the control moduleis switched on and the guntrigger is pressed.

Gun sprays powder, LED atthe rear of the cascade is dark,powder does not adhere tothe workpiece

Gun sprays powder, high-voltage present, powder doesnot adhere to the work piece.

Conveying air cannot beadjusted.

Causes

– Injector, check valve orthrottling at injector,powder hose or gun clogged

– Insert sleeve in injector isworn

– Fluidization does notfunction

No conveying air:– Reducing valve defect

– Solenoid valve defect


– High voltage too low

– Gun connector, gun cableor gun cable connector isdefect

– High voltage cascade isdefect


– Work piece not properlygrounded

Control knob turns freely onthe shaft or the grubscrewis loose.

Remedies

Clean corresponding part

Replace

See above

Replace

Replace

Mail in for repair

Increase the high voltageon the control module

Replace defective item ormail it in for repair

Mail in the shaft of thegun for repair

Mail in for repair

Check the ground connec-tion, also refer to "Safetyrules"

Tighten the grubscrew.

15MPS 1-F / MPS 2-F

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0

1

2

3

4bar

8

7

6

5

4

3

2m /h3

3.5

3

2.5

2

1.5

1

0.5

m /h3

100

90

80

70

60

50

40

30

20

10

100

90

80

70

60

50

40

30

20

10

+

0

1

kV µA

0

1

2

3

4bar

8

7

6

5

4

3

2m /h3

3.5

3

2.5

2

1.5

1

0.5

m /h3

100

90

80

70

60

50

40

30

20

10

100

90

80

70

60

50

40

30

20

10

+

0

1

kV µA

1

2

3 4

5

60

�#$*

GEMAGEMAVOLSTATICVOLSTATIC

Type

PG

1

Serial N

o. 8002

.2012

GEMAGEMAVOLSTATICVOLSTATIC

Type

PG

1

Serial N

o. 8002

.2012

Supplementary material for converting MPS 1-F to MPS 2-F

Carefully unpack the parts and check against the list below if all the necessary material hasbeen supplied.

7

✓

1. PG 1 Manual Powder Gun - compl. 9. Gun holder2. PGC 1 Powder Gun Control - compl. 10. PI 3-V Powder Injector3. Main air connection (black) 11. Main cable - 2 plugs4. Connecting plate 12. Supplementary air connection (black)5. Air connection adapter 13. Conveying air connection (red)6. Solenoid cable - 2x4 pole plug Powder hose - ø 16 / 11 mm x 6 m (not shown)7. Suction tube - complete Assorted spare parts set (not shown)8. Locking nut - PG21

10 4

2

9

8

1

2

1113 12

3

4

6

5

Figure 8


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Pneumatic diagram for MPS F-1

m001

s001

g0022-8 m /h

g0040.5-3.5 m /h

m002 m004m003

s101

m101

g101

g003

PGC 1

1.1 IN

1.2 1.3 1.4

1.1 IN

3 3

External air input1/4" B.S.P. (female)

Conveying air

Rinsing air

Gun 1

Gun 1

PGC 1 for Gun 2 (Optional)

Fluidizing air

Injector

Powder hopper

Supplementary air

GUN 1

Figure 9

17MPS 1-F / MPS 2-F

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Wiring diagram

Figure 10

Opt

o-co

uple

r

Mai

ns C

onne

ctio

n10

0-24

0 V,

50/

60 H

z

Pow

der

feed

sole

noid

val

ve

Gun

Pote

ntio

met

erw

ith p

ull s

witc

h

CB

1 V

2.X

Co

ntr

ol

Bo

ard

Switc

hing

- Vo

ltage

/C

urre

nt d

ispl

ay

H-V

actu

alva

lue

A5

B3

B1

B7

B5

B2

B6

B8

B10

B9

B12

A6

A7

A8

A9

A10

A11

B8

B11

N

240V

230V

120V

110V

100V

(200

-240

V) 0

.5 A

T(1

00-1

20V

) 1.0

AT

F10.

5 A

T

GN

D+

12V

12

34

56

PE

12

3

GN

D

H1

12

PE

S1

A4

A3

A2 A1

GN

D

K2

200V

R1

2K2

Y1

S2

(R1)

12

21

21

3

GN

D+

12V

+24

V

K1

31K

1

T1

AB

C

12

34

56

S

PG

1

PE

NC

A12

NC

GN

D

GUN

EXT

GUN

EXT

GUN

EXT

X1

X2

X3

+-

Y2

Flui

diza

tion

Sole

noid

val

ve


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NOTES:

19MPS 1-F / MPS 2-F

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Spare Parts Lists

Ordering Spare Parts

When ordering spare parts for powder coating equipment, please indicate the followingspecifications:

1. Type, and serial number of your powder coating equipment

2. Order number, quantity, and description of each spare part

Example:

1. Type MPS 1-F, Serial no : xxxx xxxx

2. Order no : 201 073, 5 pieces, fine wire fuse

When ordering cable or hose material the length required must also be given.The spare part numbers of yard/metre ware always begins with 1.. ... and are always markedwith an * in the spare parts list.

Wear parts are always marked with a #.

All dimensions of plastic powder hoses are given as external diameter (o/d), and internaldiameter (i/d) :

e.g. ø 8 / 6 mm, 8 mm outside diameter (o/d) / 6 mm inside diameter (i/d)


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PH 50-D Powder hopper for MPS 1-F / MPS 2-F

Hopper complete (without cover) 367 0951 Venting hose (without Airmover - ø 40 mm x 3 m.) 100 048#3 Hopper cover 367 001

3.1 Inspection cover complete 366 8704 Rubber seal (1.24 m) 103 837*

5 Powder hopper body 367 0876 Fluidizing plate 362 387#

6.1 Rubber seal 348 6947 Clamp band 341 9248 Fluidizing air chamber 340 8989 Elbow joint 200 875

10 Aperture disk 301 32911 Quick-release hose connector 200 85912 Quick-release connection for fluidizing air hose 203 18113 Fluidizing air hose 103 756*

14 Suction tube - complete (incl. Items 14.1 and 15) 339 13014.1 Suction tube 336 491

15 Injector support 336 48316 Lock nut 234 86917 Plug cap - Injector opening 223 22020 Plug cap - Powder recovery opening (ø 100 mm} 244 14722 Inspection cover seal (0.65 m) 103 837*

29 Venting hose adapter complete 361 41032 Hopper cover (No holes) 367 010#

* Indicate length required# Wear parts

21MPS 1-F / MPS 2-F

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Figure 11

1

4

5

6

7

8

16

15

14.1

9 11 12 13

6.1

17

14

3

��#��#13.1

7

32

29

3.1

22

10

PH 50-D Powder hopper for MPS 1-F / MPS 2-F


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Fluidizing unit

For MPS 1-F - complete 346 098(without items 9, 10, 11, 12, 13, 14, 15)For MPS 2-F - complete 346 101(without items 9, 10, 11, 12, 13, 14, 15)

1 Air connection adapter for MPS 1-F 227 8381.1 Air connection adapter for MPS 2-F 236 055

2 Air connection ring - ø 8 mm-1/4" 231 8863 Main air connection - 1/4" (female) B.S.P. thread 236 0634 Gasket - ø 13.4x18.0x1.8 mm 225 4875 Solenoid valve - compl. 242 217

5.1 Solenoid valve coil 251 0466 Pressure reducing valve 242 225

6.1 Adapter 242 2097 Pressure gauge 237 0608 Elbow connector - ø 8 mm-1/8" 242 8539 Hose for fluidizing air ø 8 / 6 mm (black) 103 756*

10 Quick-release connector - ø 8 / 6 mm 203 18111 Solenoid valve cable for MPS 1-F 336 629

11.1 Solenoid valve cable for MPS 2-F 342 25412 Screw connector 201 31613 Adapter 202 47914 Quick-release connector - 1/4" 203 10615 Fluidizing unit bracket 346 110

MPS 1-F MPS 2-F

2

2

4

6

9

1114

8

10

1

5

3

3

7

15

49

10

10

14 13

1.1

1212

12

10

5.1

9

* Indicate length required Figure 12

23MPS 1-F / MPS 2-F

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MPS 1-F - MPS 2-F

1 Control unit housing 336 5482 Gun holder 301 0863 Milled nut - M4 201 0904 Control unit support 336 2705 Base plate 336 2976 Trolley wheels 202 215

1

2

3 45

6

0

0

1

2

3

4bar

8

7

6

5

4

3

2m /h3

3.5

3

2.5

2

1.5

1

0.5

m /h3

100

90

80

70

60

50

40

30

20

10

100

90

80

70

60

50

40

30

20

10

+

0

1

kV µA

0

1

2

3

4bar

8

7

6

5

4

3

2m /h3

3.5

3

2.5

2

1.5

1

0.5

m /h3

100

90

80

70

60

50

40

30

20

10

100

90

80

70

60

50

40

30

20

10

+

0

1

kV µA

1

2

3

4

5

6

Figure 13


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Documentation MPS 1-F / MPS 2-F

© Copyright 1991 ITW Gema AG, CH-9015 St. Gall.All technical products from ITW Gema AG are constantly being developed based onour continuing research and applications.The data found in this publication may therefore change at any time without priornotification.

Printed in Switzerland

MPS 1-F / MPS 2-F Manual Powder System - eko-BHL

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Transcript of MPS 1-F / MPS 2-F Manual Powder System - eko-BHL